AU2009242961A1 - Fire rated, multi-storey, multi-dwelling structure and method to construct same - Google Patents

Description

WO 2009/132387 PCT/AU2009/000531 1 Fire Rated, Multi-Storey, Multi-Dwelling Structure and Method to Construct Same 5 TECHNICAL FIELD The present invention relates to a permanent or semi-permanent multi-dwelling structure and a method of constructing the same. In particular the invention relates to a permanent or semi-permanent fire 10 rated, multi-storey, multi-dwelling structure constructed from a plurality of building modules, which are the frames of specialty shipping containers. The present invention also relates to a method of transporting and assembling the plurality of building modules into a multi-dwelling structure. 15 BACKGROUND TO THE INVENTION Shipping containers have previously been used for housing purposes. However, most of these applications include the use of a single container 20 suitably arranged or recycled for providing a shelter. Such an arrangement is unsuitable for providing large scale accommodation in a very short time scale and with relatively low construction costs. United States Publication no. 2003/0188507 discloses modular multi use shelters constructed by assembling a plurality of shipping containers 25 converted into a multi-element structure, wherein each shipping container is joined to the rest by means of the standard mechanisms that are normally provided to interlock modular shipping containers during transportation. While multi-use structures such as prisons or jail facilities have been mentioned in this document, the system described there is limited to each 30 container being used as a relatively independent entity. The only connection between the containers disclosed in this publication refers to interior passages provided between adjacent containers. Furthermore, no indication has been given as to the arrangement of the facilities related to WO 2009/132387 PCT/AU2009/000531 2 various utilities such as supply of water electricity, heating and sewerage removal. Thus, while the large number of containers discussed there can offer a large scale of accommodation, because of the fact that each container has been used substantially independently and possibly serviced 5 individually, a lot of the potential flexibility provided by such a multi dwelling system has not been utilised. International PCT publication no. WO 2005/038155 describes building modules and buildings made from such modules. In order to address the 10 issue of the relatively confined space within the interior of previously known modular building systems utilising shipping containers, the invention described in WO 2005/038155 provides for modular building units that have an overall exterior width greater than 2700mm and includes fastening elements at a centre-to-centre spacing of about 2260mm, which is the ISO 15 spacing between the fastening elements of ISO shipping containers. The applicant of WO 2005/038155 claims that having the fastening elements at the ISO standard spacing enables the modular building units to be handled and transported by the same equipment that handles and transports standard ISO shipping containers. 20 However, because the building modules described in WO 2005/038155 do not have ISO standard external dimensions, the building units are not able to be handled in the same way that ISO shipping containers are. For example, when conventional ISO shipping containers are stacked on a 25 container ship, a freight train, a container truck or the like, the external dimensions of the containers often must fit within a space of a pre determined size. If the "footprint" of the shipping container is bigger than this space allows for, then the shipping container cannot be easily transported. The exterior width of the building modules described in 30 WO 2005/038155 are 2700mm, which is larger than the exterior width of standard ISO shipping containers.

WO 2009/132387 PCT/AU2009/000531 3 One of the major benefits of constructing a building using modular building units that conform to standard ISO shipping container dimensions and fixtures is the reduced cost of transportation of the modular building units around the world. If the modular building units are not of an ISO 5 standard, then there is an increased difficulty and associated costs in transporting the modular units from their place of manufacture to their installation site. The reason that the modular building units of WO 2005/038155 are of 10 a greater size than standard ISO shipping containers is to satisfy a long felt want in the industry of increasing the relative interior size of the rooms of buildings that are constructed from a plurality of modular building units that have a size and shape corresponding with that of ISO shipping containers. However, by increasing the exterior dimensions of the modular building 15 units, the ease of transporting the building units is diminished and therefore the associated cost of constructing a building utilising such modular building units is increased and the convenience of utilising such a system is diminished. 20 WO 2005/038155 also describes a number of different possible variations of the basic configuration of the modular building units. For example, a building unit is shown that has open end faces, a full height opening in one side and a window opening in the opposite side. Another building unit is shown that has an open side face, an opposite closed side 25 face and two end faces with window openings. Another building unit is shown that has an open side face, an open end face, with window openings in the other side and end faces. Another building unit is shown that has all its end and side faces open. 30 However, in the embodiment shown where all of the end and side faces are open, there still remains a top section of the building unit. This top section provides strength and rigidity to the building unit, particularly during transportation of the building unit from its place of manufacture to the WO 2009/132387 PCT/AU2009/000531 4 installation site. Whilst a further embodiment of the building unit having open side, end and top faces is shown, there are no horizontal edge rails as part of the frame of the building unit, extending between the vertical posts to strengthen the building unit during transportation. This may be 5 particularly problematic where multiple building units are vertically stacked on top of each other, such as is likely to occur if the building units are to be transported on a freight ship. Furthermore, under the International Building Code, the Building Code 10 of Australia, as well as many other building codes around the world, sole occupancy units must be separated by fire barriers and the structure in the building must be similarly fire protected. The modular building system described in WO 2005/038155 does not make any reference to how these International building codes, particularly relating to fire rating and 15 performance will be met. It is therefore an object of the present invention to provide a permanent or semi-permanent multi-dwelling structure and a method of constructing the same that will go someway to overcoming or substantially 20 ameliorate at least one of the deficiencies identified in the prior art or at least to provide an alternative thereto. DISCLOSURE OF INVENTION 25 According to a first aspect of the invention there is provided a building module for a permanent or semi-permanent multi-dwelling structure. The building module is of a substantially rectangular shape and has external dimensions substantially the same as an ISO shipping container. The 30 building module has a frame consisting of upper, lower and side load bearing edge rails, which define a hollow interior of a space and size suitable for occupation by a person. The building module includes at least one open side face, which has upper and lower load-bearing edge rails that WO 2009/132387 PCT/AU2009/000531 5 are adapted to engage with one or more removable brace posts. Each one of the brace posts extends from the lower load-bearing edge rail of the open side face and props up the upper load-bearing edge rail of the open side face. 5 Preferably, the removable brace posts are erected between the upper and lower load-bearing edge rails of the open side face before the building module is transported and when the building module is installed on a pre determined development site, the brace posts are removed from the 10 building module. Preferably, each of the lower load-bearing edge rails of the building module further includes a length of bottom angle secured thereto. The lengths of bottom angle are adapted to support a floor slab, which is 15 preferably made of concrete thereon. The floor slab is not secured to any of the lengths of bottom angle during transportation of the building module, thereby allowing for movement between the floor slab and each of the lengths of bottom angle. When the building module is installed on a pre determined development site, the floor slab is secured to one or more of the 20 lengths of bottom angle by fire-retardant adhesive filler. Preferably, each of the upper load-bearing edge rails includes a length of top angle secured thereto. The top angle has a T-shaped constant cross section when viewed in end view. The lengths of top angle are adapted to 25 support a fire-rated plasterboard ceiling panel. Preferably, the building modules of the present invention have a 120/120/120 fire rated structure. 30 According to a second aspect of the present invention, there is provided a method for constructing a permanent or semi-permanent multi dwelling structure from a plurality of building modules of any of the preceding paragraphs, the method having the steps of: WO 2009/132387 PCT/AU2009/000531 6 (a) using the predetermined size and shape of the building modules to define a grid of foundation points; and (b) inserting foundations at the foundation points. 5 Preferably, the method further comprises the steps of affixing a plurality of building modules in an adjacent and/or stacked configuration, each building module being affixed to foundation points and/or to an adjacent building module, such that a plurality of complimentary building modules forms an integral part of a single dwelling. 10 According to a third aspect of the present invention, there is provided a method of manufacturing, transporting and constructing a permanent or semi-permanent multi-dwelling structure having the steps of: is (a) at an "offsite" location from where the multi-dwelling structure is to be constructed, manufacturing building modules, each of the building modules having a substantially rectangular shape and having external dimensions substantially the same as an ISO shipping container, each one of the building modules having load 20 bearing edge rails defining a hollow interior of a space and size suitable for occupation by a person, wherein each one of the building module includes at least one open side face having upper and lower load-bearing edge rails and wherein each of the lower load-bearing edge rails further includes a length of bottom angle 25 secured thereto, the length of bottom angle being adapted to support a floor slab thereon; (b) installing one or more removable brace posts that are adapted to engage with the upper and lower load-bearing edge rails of the open 30 side face, whereby each one of the brace posts extends from the lower load-bearing edge rail of the open side face and props up the upper load-bearing edge rail of the open side face; WO 2009/132387 PCT/AU2009/000531 7 (c) transporting the building modules from the location where the building modules are manufactured to a site where the multi dwelling structure is to be constructed, the building modules are 5 transported by one or more of the following, ISO equipped container ships, ISO equipped container trains and/or ISO equipped container trucks; (d) at the site where the multi-dwelling structure is to be constructed, 10 using the predetermined size and shape of the building modules to define a grid of foundation points and inserting foundations at the foundation points; (e) removing the brace posts that are installed between the upper and 15 lower load-bearing edge rails of the open side faces of each the building modules; (f) affixing the building modules to foundation points and/or to an adjacent building module in an adjacent and/or stacked 20 configuration; (g) securing the floor slab to one or more of the lengths of bottom angles by pouring fire-retardant adhesive filler therebetween; and 25 (h) optionally installing one or more internal dividing walls to create separate single occupancy dwellings within joined adjacent building modules. Preferably, during the manufacturing of the building modules in step 30 (a), the roof section of each of the building modules remains substantially open to allow large furniture components to be installed into each of the building modules by lowering the components into the building module through the open roof section.

WO 2009/132387 PCT/AU2009/000531 8 Preferably, the roof section is closed before the building module is transported. 5 Preferably, before the building modules are transported in step (c), each one of the building modules is wrapped in a vacuum sealed plastic to protect the internal finishes of the building modules. 10 BRIEF DESCRIPTION OF THE DRAWINGS Preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which: 15 FIG 1 is a perspective view of a building module according to one aspect of the invention. FIG 2 is a cross-sectional view of two adjacent building modules as 20 depicted in FIG 1, shown in end view. FIG 3 is a cross-sectional view of three adjacent building modules as depicted in FIG 1, shown in end view. 25 FIG 4 is a perspective view of a building module as depicted in FIG 1 with a plurality of removable brace posts erected between the upper and lower load-bearing edge rails of the open side face of the building module. FIG 5 is a cross-sectional view of three adjacent building modules as 30 depicted in FIG 1, shown in end view with carpet installed.

WO 2009/132387 PCT/AU2009/000531 9 FIG 6(a) is an enlarged schematic plan view of foundation points for constructing a permanent or semi-permanent multi-dwelling structure according to one aspect of the invention. 5 FIG 6(b) is an enlarged schematic side view of a foundation pile engaging a building module in a supporting arrangement, according to one aspect of the invention. FIG 6(c) is an enlarged schematic plan view of the supporting 10 arrangement of FIG 6(b). FIG 7 is a schematic front elevation view of a three storey dwelling structure according to a first embodiment of the invention. i5 FIG 8 is a plan view of a permanent or semi-permanent multi dwelling structure according to a second embodiment of the invention. FIG 9 is a schematic plan view of permanent or semi-permanent multi-dwelling structure according to a third embodiment of the invention, 20 wherein three units complement each other to form a single dwelling. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 25 The present invention generally relates to a permanent or semi permanent multi-dwelling structure and a method of constructing the same. In particular the invention relates to a permanent or semi-permanent fire rated, multi-storey, multi-dwelling structure 1 constructed from a plurality of building modules 2, which are specialty shipping containers. The present 30 invention also relates to a method of transporting and assembling the plurality of building modules 2 into a multi-dwelling structure 1.

WO 2009/132387 PCT/AU2009/000531 10 As shown in FIGS 1 to 9, the permanent or semi-permanent multi dwelling structure 1 of the present invention is constructed from a plurality of building modules 2, which are specialty shipping containers. The specialty shipping containers have an external size and shape compatible to ISO 40' x s 8' or ISO 20' x 8' shipping containers. As best shown in FIG 1, each of the building modules 2 has a frame consisting of upper, lower and side load-bearing edge rails (3, 4 and 5 respectively). The frame of each of the building module 2 defines a hollow 10 interior 6 of a space and size suitable for occupation by a person. The building modules 2 are fabricated in a container fabrication facility, which is generally in a different location to where the multi-dwelling structure 1 is to be constructed. Additional arrangements such as fitting claddings, insulation, or including any other utility arrangements, can also be 15 performed at the place of fabrication. Of course, any required components can also be fabricated at different places and delivered for fitting at the place of installation. Because of its specific nature, the corresponding method of construction of the multi-dwelling structure 1, is also very specific. An important aspect of its construction is a fast, cheap and reliable 20 installation, whereby a minimum amount of labour, and in particular skilled labour, is required. Each of the building modules 2 have at least one open side face 14, although in many cases the building modules will have both side faces open. 25 The open side face 14 has upper and lower load-bearing edge rails 3, 4 and vertical side load-bearing edge rails 5. Both the upper and lower load-bearing edge rails 3, 4 are adapted to engage with one or more removable brace posts 15. The removable brace 30 posts 15 are extendible "Acrow" props that are initially shorter than the span between the upper and lower load-bearing edge rails 3, 4, but which extend out to engage with both the upper and lower load-bearing edge rails. The brace posts 15 are erected between the upper and lower load- WO 2009/132387 PCT/AU2009/000531 11 bearing edge rails 3, 4 of the open side face 14 during the manufacturing stage of the building modules 2 and serve to prop up the upper load bearing edge rail of the open face during transportation of the building module. This arrangement is best shown in FIG 4. 5 When the building module 2 is installed on a pre-determined development site, where a multi-dwelling structure 1 is to be constructed, the brace posts 15 are removed from between the upper and lower load bearing edge rails 3, 4. 10 During manufacture of the building modules 2, the roof section 7 of the building module is kept open to allow large furniture components, such as prefabricated kitchen units, prefabricated bathroom units, appliances, carpets, bed frames and the like, to be installed into the building modules 15 by lowering the components into each of the building modules through the open roof section. Before the building modules 2 are transported from the location where the building modules are manufactured, the roof section 7 of each of the building modules is closed and a fire rated ceiling is installed on the interior underside of the roof section. 20 As best shown in FIG 2, each of the upper load-bearing rails 3 of the building module 2 includes a length of top angle 8 secured thereto. The length of top angle 8 is adapted to support a fire rated plasterboard ceiling panel, which spans across the interior side of the roof section 7 of an 25 individual building module 2. When viewed in end view, the lengths of top angle 8 have a "T-shaped" constant cross section. The final finish of the interior side of the ceiling can be completed entirely before the building modules 2 are transported from the location where they are manufactured to a development site, where a multi-dwelling structure 1 is to be 30 constructed. To minimise potential damage to the final finish of the interior of the building modules 2, and particularly to the final finish of the interior of the ceiling, before the building modules are transported, they are typically wrapped in vacuum sealed plastic.

WO 2009/132387 PCT/AU2009/000531 12 It can also be seen in FIG 2 that each of the lower load-bearing rails 4 of the building module 2 includes a length of bottom angle 9 secured thereto. The length of bottom angle 9 is adapted to support a concrete floor 5 slab 10 thereon. When viewed in end view, the lengths of bottom angle 9 have an "L-shaped" constant cross-section. When the building modules 2 are manufactured, the concrete floor slab 10 is installed in the base of a building module by resting the slab on the bottom lengths of angle 9 secured to the lower load-bearing edge rails 4. In this way, the floor slab 10 10 is not secured to the bottom length of angle 9 and the slab can move a small amount relative to the bottom lengths of angle and the lower load bearing edge rails 4. This is particularly useful when the building modules 2 are 15 transported from their location of manufacture to a location at which the building modules will be used in the construction of a multi-dwelling structure 1. This is because as there is a degree of movement between the floor slab 10, the bottom lengths of angle 9 and the lower load-bearing edge rails 4, the possibility of the concrete floor slab cracking or splintering 20 as a result of the stress forces that are applied on the slab during transportation of the building modules 2 is reduced. As best shown in FIG 3, when the building modules 2 are installed at a pre-determined development site, the floor slab 10 is secured to the 25 bottom lengths of angle 9 by pouring fire-retardant adhesive filler 11 between the concrete floor slab and the bottom lengths of angle. Adjacent building modules 2 are connected together via the ISO shipping container corner connectors 12 in a conventional manner. When adjacent building modules 2 are connected together via connectors 12, a recess 13 is formed 30 in the vicinity of the connectors that are locked together. This can be seen in FIG 3, where it is shown that the depth of concrete floor slab 10 extends beyond the height of the locked connectors 12, thereby forming the recess 13. After the adjacent building modules 2 have been joined together via WO 2009/132387 PCT/AU2009/000531 13 their respective connectors 12, this recess 13 is filled in with the same fire retardant adhesive filler 11 that is used to secure the floor slab 10 to the bottom lengths of angle 9. 5 In this way, whilst the floor of the multi-dwelling structure 1 consists of the floor slabs 10 of adjacent building modules 2 and the in-filled recesses 13 formed between adjacent building modules, the floor is nevertheless substantially the same level and is relatively flat. Floor coverings, such as carpet, linoleum, floating floorboards or the like can be 10 installed over the concrete floor slab 10 when the building modules 2 are manufactured. In this way, after the fire-retardant adhesive filler is poured between adjacent building modules 2 and the floor of the multi-dwelling structure 1 is at least partially finished, the floor covering can simply be extended to cover recess 13, formed between adjacent building modules 2, 15 that has been "in filled" by fire-retardant adhesive filler. For example, as shown in FIG 5, where a floor covering in form of carpet 38 has been installed in the building modules 2, it is conceived that the carpet can be adhered to the floor slab 10 with a free end of excess 20 carpet being left "rolled up" and unattached to the floor. The unsecured portion of.the carpet 38 corresponds to where the building module 2 will be joined to an adjacent building module. Thus, during the construction of the multi-dwelling structure 1, the 25 rolled up carpet 38 can then quickly and easily be adhered to the recess 13, formed between adjacent building modules 2, that has been "in filled" by fire-retardant adhesive filler. This reduces the manufacturing, and more particularly the installation and construction costs, as well as substantially reducing the time involved in constructing a multi-dwelling structure 1 when 30 compared to the construction of a conventional building.

WO 2009/132387 PCT/AU2009/000531 14 Each of the building modules 2, as well as the multi-dwelling structure 1, which is constructed from a plurality of the building modules satisfy International and most national fire ratings. 5 Building structures are classified according to their Fire Resistance Level as required by Australian and International Standards, the Building code of Australia (BCA) and the International Building Code (IBC 9). Fire Resistance Levels, or FRL's for short, are a series of numbers that describe the ability of a certified product to resist the spread of fire. For example, a 10 typical fire rated wall may have a fire resistance level of 120/120/120. The first number of a FRL simply refers to how long the product can withstand the spread of fire and still support what it is designed to support. The second number refers to the ability to prevent the spread of flames. The final number refers to the length of time that the product can prevent the 15 spread of fire due to heat transfer. The building modules 2 of the present invention are rated at the highest level of fire resistance and have a FRL of 120/120/120, obtaining the maximum rating in each of the three categories. 20 Usually the pre-determined development site where a multi-dwelling structure 1 is to be constructed is prepared by using bulldozers to level the site. While the building modules 2 can be directly installed on the ground, this method is not suitable for the permanent or semi-permanent structure discussed in this application and is not recommended. The preferred 25 installation method includes preparing the ground, where the multi-dwelling structure 1 will be constructed, by installing a grid of foundation points, as indicated in FIG 6(a). The grid of foundation points is determined based on the predetermined size and shape of the building modules, as well as the desired overall layout of the multi-dwelling structure 1. Screw pile or other 30 suitable machines may be used to form the foundations for the multi dwelling structure 1. The foundations are usually formed to correspond to the corner points of the corresponding building modules 2, so as to take advantage of the ISO corner connectors 12 in the corners of the building WO 2009/132387 PCT/AU2009/000531 15 modules. It is envisaged that pre-manufactured slabs arranged to secure the corners of the building modules 2 could also be laid next to and connected to each other so as to form a foundation, suitable for attaching the building modules thereto. 5 After the foundations have been formed, the site is ready for securing the building modules 2 thereto. Once the building modules 2 have been transported near the site, a mobile crane can lift the pre-finished modules directly into permanent position on the prepared screw piles. Alternatively, 10 although not preferred, the building modules can also be stacked as normal containers to a nominal height of up to three levels/storeys. The specific arrangement for attaching the units to the foundation piles is as follows. Firstly, piles 16, chosen to suit the local ground conditions, are inserted in the foundation points. As shown in FIG 6(a), some of the piles 16 are used is to support a single, usually a corner, building module 2. The piles 16 that support internal building modules 2 would be arranged to engage with two adjacent building modules, as indicated in FIGS 6(a) and 7. As shown in FIG 6(b), the pile caps 17 include grout, which is 20 expandable so as to be able to accommodate temperature variations. The pile cap plate 18 is attached on the top of the expandable grout. If necessary, shims 19 may be used to level the upper surface of the pile cap plate 18. A base plate 20 is then attached to the pile cap plate 18 by means of base plate bolts 21. The base plate 20 usually includes a nipple 25 22, which is arranged for a complimentary engagement with a dent 23 at the bottom of the supported building module 2. The building module 2 is bolted to the base plate 20 by means of high tensile bolts 24. The combination of nipples 22 and high tensile bolts 24 provides a flexible, yet strong connection, which is both cyclone and earthquake resistant. 30 Depending on the position of the respective pile 16, there are several possible arrangements of the pile base plates 20. If the pile 16 is supporting a corner building module 2, a single nipple 22 and a high tensile WO 2009/132387 PCT/AU2009/000531 16 bolt 24 arrangement is required. On the other hand, where two building modules 2 are adjacent to each other, the corresponding supporting base plate 20 is arranged to have two nipples 22 and two high tensile bolt 24 arrangements, so as to hold both building modules in place next to each 5 other. This is best shown in FIG 7 and is indicated in Figure 6(c). After the building modules 2 have been attached to the foundation points, the building modules are then further attached to each other in a standard manner, such that each building module is attached to 10 corresponding foundation points and/or to other building modules so as to define the multi-dwelling structure 1. As best shown in FIG 7, the multi dwelling structure is preferably a multi-storey building. The multi-dwelling structure 1 is most cost effective and has the most commercially viable construction time to size of building ratio when the structure is eight is storey's high. Although, it should be understood that multi-dwelling structures 1 can be constructed that are up sixteen storey's high, the maximum load level of the building modules 2. The multi-dwelling structure 1 represented in the accompanying 20 figures is a permanent or semi-permanent large-scale housing complex where at least some of the dwellings share common facilities. The shared facilities could include transport facilities such as access ways or stairways to the upper storey dwellings. Utility services such as provision of water, heating, gas and electricity or the removal of sewerage are also usually 25 shared between two or more dwellings. In addition, the facilities are in a modular form wherein the modularity relates to the entire structure. For example, a water or electricity supply system is arranged in modules, which are particularly designed to fit and be installed in the context of the multi dwelling system constructed by a plurality of building units/modules. 30 Once the building modules 2 have been affixed to the foundations and/or to other building modules, the next step is the installation of the various utility services, such as water, heating, gas and electricity supply or WO 2009/132387 PCT/AU2009/000531 17 sewerage removal. As discussed above, the advantage of the system of the present invention is that it utilises facilities that are common for more than one dwelling. In a preferred situation, a single facility module/unit would service the entire multi-dwelling structure. 5 It is also important that these common facility structures/units are in a modular form, which takes into account the multi-dwelling character of the multi-dwelling structure 1 of the present invention. This would allow a much larger scale and much more efficient installation of the facilities. Any 10 type of other facilities such as steel stairs, access ways, rainwater collection tanks and structures, roofs, domestic water header tanks, solar electricity panels installed on the roofs, lighting, solar hot water heaters, gas cooking facilities, septic tanks and so on may also be in a modular form. is In particular, the multi-dwelling structure 1 of the present invention has a centralised fire isolated duct riser that provides ventilation and exhausts stale air from the structure. The ducts can also be used to provide chilled water to air conditioners and exhaust steam from the bathrooms of each of the single occupancy dwellings in the multi-dwelling structure 1. It 20 is preferred that the multi-dwelling structure 1 will have a top plant room located on the roof of the structure that is serviced by the centralised duct risers. The centralised duct risers are fire-rated to maintain the FRL of the multi-dwelling structure 1 of 120/120/120. The centralised duct risers achieve their fire rating by having a double lining of fire rated plasterboard. 25 It should be appreciated that the disclosed permanent or semipermanent multi-dwelling structure constructed from a plurality of modular units provides a quick, relatively cheap and reliable way of providing a large scale accommodation with the associated utility services 30 within a small budget and a very short time period. In addition, should there be a need for the units to be moved or totally relocated, the units and the roofs are simply unbolted, the units being loaded onto semi-trailers, or WO 2009/132387 PCT/AU2009/000531 18 their own bogies are reactivated, and the units are transported to their new location, where they are re-assembled in the above described manner. Whilst the embodiments described above and shown in the 5 accompanying drawings depict ceiling panels that are made of fire-rated plasterboard, it should be understood that any suitable type of fire-rated material can be used. In other embodiments not shown in drawings, insulation may also be installed in the ceiling to provide thermal, acoustic and improved fire-resistant properties. It should also be understood that the 10 floor slab can be made of any other suitable material, other than the concrete slab that is described above and depicted in the accompanying drawings. In other embodiments not shown in the drawings, the cross-sectional 15 shape of the lengths of top and bottom angle may be different to the respective "T" and "L" shapes shown in the drawings. Indeed, it is envisaged that other suitable mechanisms of attaching both the ceiling panels and the floor slab to the building modules 2 of the invention may be utilised. 20 In this specification, unless the context clearly indicates otherwise, the term "comprising" has the non-exclusive meaning of the word, in the sense of "including at least" rather than the exclusive meaning in the sense of "consisting only of". The same applies with corresponding grammatical 25 changes to other forms of the word such as "comprise", "comprises" and so on. Although the invention is described above with reference to specific embodiments, it will be appreciated by those skilled in the art that it is not 30 limited to those embodiments, but may be embodied in many other forms. Two particular examples of a typical layout of the building modules 2 forming a multi-dwelling structure 1 are shown in FIGS 8 and 9.

WO 2009/132387 PCT/AU2009/000531 19 EXAMPLE 1 The multi-dwelling structure 1 shown in FIG 8 comprises: 5 Unit A 1 x 40' container frame with open glazed ends, one long side with a window of solid corrugated steel, clad on the outside with fibre cement and on the inside with fire rated plasterboard, one long side open 10 Unit B 1 x 40' container frame with open glazed ends, both long sides open Unit C 1 x 40' container frame with open glazed ends, one long side of structural is steel stud framed wall clad on both sides with fire rated plasterboard and one long side open Unit D 1 x 40' container frame with open glazed ends, both long sides open and a 20 central fire rated corridor Unit E 1 x 20' container frame with one open glazed end, one solid end inside with fire rated plasterboard, one long side with a plasterboard wall and one long 25 side open Unit F 1 x 20' container frame with one open glazed end, one solid end inside with fire rated plasterboard, one long side of structural steel stud framed wall 30 clad on both sides with plasterboard and one long side open WO 2009/132387 PCT/AU2009/000531 20 Unit G 1 x 20' container frame with one open glazed end, one solid end inside with fire rated plasterboard and both long sides open 5 Unit H 1 x 20' container frame with one open glazed end, one solid end inside with fire rated plasterboard and both long sides open Unit I 10 1 x 20' container frame with one open glazed end, one solid end inside with fire rated plasterboard wall and enclosed cupboard for risers and both long sides open Unit J 15 1 x 20' container frame with one open glazed end, one solid end inside with fire rated plasterboard wall and both long sides open Unit K 1 x 20' container frame with part open side walls, one solid end for external 20 classing as for Unit A, one central wall of structural steel stud framed wall clad on both sides with fire rated plasterboard, fire rated walls enclosing a steel structured lift shaft with recessed door/wall to an open end facing the corridor 25 Unit L 1 x 20' container frame with one solid end for external cladding as for Unit A, both long side walls of structural steel framed wall clad on both sides with fire rated plasterboard enclosing a steel structured concrete stair and fire door/garbage wall facing the corridor 30 WO 2009/132387 PCT/AU2009/000531 21 Unit M 1 x 20' container frame with one open glazed end, one solid end inside with fire rated plasterboard wall and enclosed cupboard for risers and both long sides open 5 Unit N 1 x 20' container frame with one open glazed end, one solid end inside with fire rated plasterboard wall and both long sides open 10 Unit 0 1 x 20' container frame with one open glazed end, one solid end inside with fire rated plasterboard and both long sides open Unit P 15 1 x 20' container frame with one open glazed end, one solid end inside with fire rated plasterboard and both long sides open Unit Q 1 x 20' container frame with one open glazed end, one solid end inside with 20 fire rated plasterboard, one long side with a plasterboard wall and one long side open Unit R 1 x 20' container frame with one open glazed end, one solid end inside with 25 fire rated plasterboard, one long side of structural steel stud framed wall clad on both sides with plasterboard and one long side open Unit S 1 x 40' container frame with open glazed ends, both long sides open and a 30 central fire rated corridor WO 2009/132387 PCT/AU2009/000531 22 Unit T 1 x 40' container frame with open glazed ends, one long side of structural steel stud framed wall clad on both sides with fire rated plasterboard and one long side open 5 Unit U 1 x 40' container frame with open glazed ends, both long sides open Unit V 10 1 x 40' container frame with open glazed ends, one long side with a window, of corrugated steel clad on the outside with fibre cement and on the inside with fire rated plasterboard and one long side open 15 EXAMPLE 2 The structure 1 shown in FIG 9 comprises three adjacent building modules 2 (Units A, B and C), which are joined together to form a single dwelling. Unit A comprises an office/study 25, a laundry 26 and a kitchen 27 20 having a cooktop 28 and fridge 29. Unit B comprises a vestibule 31 and a staircase 32. Unit C comprises a media room 33, a guest bathroom 34, a dining room 35 and a living room 36. A porch 30 is installed at one end of the dwelling and a verandah 37 is installed at the opposite end of the dwelling 1. Both the porch 30 and the verandah 37 span across adjacent, 25 joined building modules 2. INDUSTRIAL APPLICABILITY 30 The internal layouts and external design of the building modules 2 and the resultant multi-dwelling structure 1 corresponds to the specific purpose of the dwellings and the budget available. With regard to the purpose of the WO 2009/132387 PCT/AU2009/000531 23 dwellings it is envisaged that several different types of dwellings can be designed and constructed, including the following: - Dwellings for special housing such as disaster relief and the like; 5 - Dwellings for mining and remote area housing; - Dwellings for low income and subsidised housing; - Communal dwellings, such as retirement homes; and - Dwellings for medium density, two storey dwelling units for general or special purposes, such as accommodating people with disabilities.

Claims (22)

1. A building module for a permanent or semi-permanent multi-dwelling structure, the building module being of a substantially rectangular shape and having external dimensions substantially the same as an ISO shipping container, the building module having a frame consisting of upper, lower and side load-bearing edge rails defining a hollow interior of a size and space suitable for occupation by a person, the building module including at least one open side face, having upper and lower load-bearing edge rails that are adapted to engage with one or more removable brace posts, which extends from the lower load bearing edge rail of the open side face and props up the upper load bearing edge rail of the open side face.

2. A building module of claim 1 wherein the removable brace posts are erected between the upper and lower load-bearing edge rails of the open side face before the building module is transported.

3. A building module of claim 2 wherein when the building module is installed on a pre-determined development site, the brace posts are removed from the building module.

4. A building module of claim 1 wherein each of the lower load-bearing edge rails further includes a length of bottom angle secured thereto for supporting a floor slab.

5. A building module of claim 4 wherein the floor slab is made of concrete.

6. A building module of claim 4 wherein the bottom angle has an L shaped constant cross-section when viewed in end view. WO 2009/132387 PCT/AU2009/000531 25

7. A building module of claim 4 wherein the floor slab is not secured to the length of bottom angle during transportation of the building module, thereby allowing for movement between the floor slab and each of the length of bottom angle.

8. A building module of claim 4 wherein when the building module is installed on a pre-determined development site, the floor slab is secured to the length of bottom angle.

9. A building module of claim 8 wherein the floor slab is secured to the length of bottom angle by fire-retardant adhesive filler.

10. A building module of claim 1 wherein each of the upper load-bearing edge rails includes a length of top angle secured thereto for supporting a ceiling panel.

11. A building module of claim 10 wherein the top angle has a T-shaped constant cross-section when viewed in end view.

12. A building module of claim 11 wherein the ceiling panel is fire-rated plasterboard.

13. A building module of claim 1 having a 120/120/120 fire rated structure.

14. A method for constructing a permanent or semi-permanent multi dwelling structure from a plurality of building modules of claim 1, the method having the steps of: (a) using the predetermined size and shape of the building modules to define a grid of foundation points; (b) inserting foundations at the foundation points; and WO 2009/132387 PCT/AU2009/000531 26 (c) affixing a plurality of the building modules in an adjacent and/or stacked configuration, each building module being affixed to one or more foundation points and/or to an adjacent building module.

15. A method of claim 14 such that a plurality of complimentary building modules forms an integral part of a single dwelling.

16. A method of manufacturing, transporting and constructing a permanent or semi-permanent multi-dwelling structure having the steps of: (a) at an "offsite" location from where the multi-dwelling structure is to be constructed, manufacturing a plurality of building modules, each one of the building modules having: - a substantially rectangular shape with external dimensions substantially the same as an ISO shipping container, - load-bearing edge rails defining a hollow interior of a size and space suitable for occupation by a person - at least one open side face having upper and lower load bearing edge rails and wherein each of the lower load-bearing edge rails further includes a length of bottom angle secured thereto, adapted to support a floor slab; (b) installing one or more removable brace posts that are adapted to engage with the upper and lower load-bearing edge rails of the open side face of each of the building modules, whereby each one of the brace posts extends from the lower load-bearing edge rail of the open side face and props up the upper load bearing edge rail of the open side face; (c) transporting the building modules by one or more of the following, "ISO equipped container ships, ISO equipped WO 2009/132387 PCT/AU2009/000531 27 container trains and/or ISO equipped container trucks" from the location where the building modules are manufactured to a site where the multi-dwelling structure is to be constructed; (d) using the predetermined size and shape of the building modules to define a grid of foundation points and inserting foundations at the foundation points at the site where the multi-dwelling structure is to be constructed; (e) removing the brace posts that are installed between the upper and lower load-bearing edge rails of the open side faces of each the building modules; (f) affixing the building modules to one or more of the foundation points and/or to an adjacent building module in an adjacent and/or stacked configuration; (g) securing each one of the floor slabs to one or more of its respective length of bottom angle by pouring fire-retardant adhesive filler therebetween; and (h) optionally installing one or more internal dividing walls to create separate single occupancy dwellings within joined adjacent building modules.

17. A method of claim 16 wherein during the manufacturing of the building modules in step (a), the roof section of each of the building modules remains substantially open to allow large furniture components to be installed into each of the building modules by lowering the components into the building module through the open roof section.

18. A method of claim 17 wherein the roof section is closed before the building module is transported. WO 2009/132387 PCT/AU2009/000531 28

19. A method of claim 16 wherein before the building modules are transported in step (c), each one of the building modules is wrapped in a vacuum sealed plastic to protect the internal finishes of the building modules.

20. A building module for a permanent or semi-permanent multi-dwelling structure substantially as hereinbefore described with reference to any one or more of the Examples and accompanying drawings.

21. A method for constructing a permanent or semi-permanent multi dwelling structure from a plurality of building modules substantially as hereinbefore described with reference to any one or more of the Examples and accompanying drawings.

22. A method of manufacturing, transporting and constructing a permanent or semi-permanent multi-dwelling structure substantially as hereinbefore described with reference to any one or more of the Examples and accompanying drawings.